JPH01248674A - Manufacture of photovoltaic element - Google Patents

Abstract

PURPOSE:To decrease manhours by simultaneously cutting a first substrate, a second substrate for protecting the surface and a third substrate for reinforcement and holding and arraying a plurality of solar cells singly separated on a fourth substrate in a matrix manner. CONSTITUTION:All of laminated substrates up to first - third substrates 1-3 except a fourth substrate 4 are cut into laminated multi-layer boards, and a plurality of independently detached photovoltaic element 5 are arranged and held onto the fourth substrate 4, thus manufacturing the title photovoltaic element. When a solar cell is used as the photovoltaic element 5, terminal sections 6 at a positive pole and a negative pole are fitted at both ends of the photovoltaic element normally, and leads are led out to the terminal sections 6 through a heat seal method and soldering. The leads can be led out in such a manner that sections laminated onto the terminal sections and superposed to the terminal sections are employed previously as opening sections 7 in the second - fourth substrates 2-4 laminated onto the first substrate. Accordingly, the manufacture of the photovoltaic element in which processes are treated continuously by the substrates in large size is acquired, thus reducing the complicatedness of the treatment of each photovoltaic element in conventional devices and the manhours.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a method for manufacturing photovoltaic elements such as solar cells and line sensors.

2. Description of the Related Art Materials such as single crystal Si, polycrystalline Si, and amorphous Si are used in solar cells and have been industrialized. When using single-crystal Si or polycrystalline St, a wafer having a size of several inches and a thickness of several hundred microns is manufactured by forming a pn junction using a thermal diffusion process. Therefore, the wafer has a structure that also serves as a photovoltaic portion and a substrate.

When using amorphous Si, amorphous St becomes crystalline St.
Since it is a low-temperature process, a structure in which a translucent soda glass is used as a substrate and a pin junction of a photovoltaic part is formed on this substrate is often used. When forming amorphous Si on soda glass, the substrate size is 1 inch, whereas crystalline silicon is currently several inches wide.
It is possible to have a thickness of several tens of inches to several tens of inches, which has a great advantage in increasing the area. Amorphous St used for power supply for calculators
The size of the solar cell is approximately 5c1n in width and 1cr11 in height.

Solar cells of this size are usually manufactured by forming multiple solar cells in a vertical and horizontal matrix on a single large sheet of soda glass, and then separating them into single solar cells using a glass scriber, as shown in Figure 3. do. Furthermore, since amorphous S1 is a low-temperature process, it can also be formed on transparent or colored heat-resistant resin films, and multiple solar cells can be produced from a single large-sized resin film substrate using the same manufacturing process as above. Can be manufactured. After separating the large substrate into a single solar cell, measurements and lead wires are attached.

The usual work method is to individually inspect the products, and in the packaging process, store them on a predetermined pallet that can accommodate a large number of products, and then ship them.

Problems to be Solved by the Invention As mentioned above, large-sized substrates can be used for amorphous Si solar cells, and many solar cells can be manufactured from the same substrate. The problem is that the separated solar cells are separated and processed individually in the post-process, which is complicated and takes a lot of man-hours, which increases costs. However, there were problems in that the individual elements were bent or bent, making processing difficult.

Means for Solving the Problems The present invention is directed to a first substrate on which a solar cell (photovoltaic element) is formed, or a multilayer board consisting of this first substrate and a second substrate for surface protection, or a reinforcing substrate. A multilayer board in which a third board is laminated is laminated on a separate board, and in this laminated multilayer board, the first board or the first board and a second board for surface protection and/or a second board for reinforcement are stacked. By cutting the three substrates at the same time, a plurality of single solar cells are held in a matrix on the fourth substrate for separation.

It is something that is arranged.

Function By cutting one or more substrates laminated on the fourth substrate for separation as described above, it is possible to hold the separated solar cells in a fixed position on the fourth substrate for separation. .

Example The present invention will be described in detail below based on the drawings.

FIG. 1 shows a conceptual diagram for implementing the present invention. A plurality of photovoltaic elements 6 are formed on a first substrate 1 made of glass or resin film. The photovoltaic element 5 is suitably an amorphous Si solar cell that can be manufactured on glass or resin film by a low-temperature process and is widely used industrially in calculators and the like.

For the first substrate, a glass plate such as soda glass, pyrex glass, or quartz glass, or a film made of polyimide, polyethylene terephthalate, polyether sulfone, or the like can be used.

The conditions for forming this solar cell were as follows: a transparent electrode made of indium oxide was formed on a glass or heat-resistant resin substrate by about 700 people using, for example, an electron beam evaporation method, and then a p-type layer of amorphous S1 was formed using a plasma CVD method. Approximately 100 L-type layers and N-type layers, 5oo
A device with guaranteed reliability was created by forming 2000 A/, Cr, and Ti electrodes using electron beam evaporation, and then using epoxy resin and passivation. Can be manufactured. - A third substrate 3 for reinforcing the second substrate for surface protection is laminated on the light incident side and the opposite side of the first substrate 1. a second substrate;
The material of the third substrate may be polyester or acrylic film, and the film thickness may be about 0.1 to 0.2 mm. Then, in order to paste and laminate the first substrate 1 and the second and third substrates, an adhesive is applied between the first substrate 1 and the second substrate 2 and between the first substrate 1 and the third substrate 3. An adhesive layer containing the adhesive layer is interposed.

This method of interposing the adhesive layer is possible by pasting the second substrate 2 or the third substrate 3 on which the adhesive layer is laminated in advance. Next, a multilayer board in which the first to third substrates are laminated is attached and laminated on the fourth substrate for separation. The laminating method for pasting is carried out in the same manner as the method for laminating the first substrate and the second substrate. As described above, the first to third substrates can be stacked on the fourth substrate. In this example, an example was described in which the first to third substrates were laminated on the fourth substrate for separation, but in addition to this example, only the first substrate on which a photovoltaic element was formed on the fourth substrate was laminated. In this case, a multilayer board consisting of the first substrate and a second substrate for surface protection is laminated on the fourth substrate, or
It is also possible to laminate a multilayer board including a first substrate and a third reinforcing substrate on the substrate. In these substrates, for example, it is also possible to implement the case where the first to fourth substrates are all resin films, or the fourth substrate is a resin film and the first substrate is a glass substrate.

By cutting these laminated multilayer plates, all the other laminated substrates from the first to third substrates except the fourth substrate are cut, and a plurality of photovoltaic cells are separated independently on the fourth substrate. Can be manufactured by holding elements in an array. In the case of a solar cell as a photovoltaic element, terminal portions 6 of ten poles and a negative pole are usually provided at both ends of the element, and leads are taken out from the terminal portions 6 by heat sealing or soldering. In order to make this lead extraction possible, the second and third substrates are laminated on the first substrate. This can be carried out by forming the hole 7 in advance in the portion of the fourth substrate that is laminated on the terminal portion and overlaps the terminal portion.

As mentioned above, since the corresponding part with the lead terminal part is opened, this terminal extraction part is printed with Aq paste, C paste), Ni paste, and solder paste.

A conductive layer can be applied using a method such as applying a conductive layer using Cu paste (Ag/Cu paste), a method using an electroless plating method to apply a conductive layer of Ni, Cu, or Ag, or a conductive layer using a solder dip or solder reflow method. It can enhance the properties and adhesion to the substrate.

FIG. 2 shows an embodiment of the present invention in which the first to third substrates are laminated on the fourth substrate for separation 4, and then the first to third substrates are laminated on the fourth substrate for separation.
The third substrate 3 is cut and a plurality of solar cell elements formed on the first substrate 1 are adhered to and held on the fourth substrate and then separated separately. This is an opening for taking out lead terminals in a state where four boards are stacked.

Although the explanation above uses an amorphous St solar cell as an example of a photovoltaic element, the present invention can also be applied to color sensors, -dimensional image sensors, etc. that use amorphous Si materials and apply pin junctions and photoconductivity. Manufacturing process available.

Effects of the Invention As described above, in the present invention, a plurality of elements can be arranged and held on a separate substrate, so the following effects can be expected. ■ Since the device manufacturing method uses a dog-sized substrate to process the entire process, it is possible to reduce the complexity and man-hours required to process conventional devices, resulting in significant cost reductions. (2) Since an adhesive layer is interposed between the laminated substrates, when individual elements are taken from a large-sized substrate and mounted on a device, they can be fixed to the device side more reliably and firmly than before. ■
In particular, in the case of heat-resistant resin film substrates, the flexibility causes the substrate to bend or bend, making it difficult to handle during the process. , handling becomes easier.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of each substrate according to the present invention before being laminated, FIG. 2 is a perspective view of the substrate after being laminated, and FIG. 3 is a perspective view of a solar cell separated in FIG. 1. 1... First substrate, 6... Photovoltaic element formed on the first substrate, 2... Second substrate for reinforcement, 3... Third substrate for surface protection, 4...
- Fourth substrate for separation, 6... Lead terminal portion, 7... Opening portion. Name of agent: Patent attorney Toshio Nakao and one other person
1st substrate 4 - 4th substrate 5 - 1st substrate C; Formed optical 8 power element/-m - 1st base plate 7 - Measuring section 8 - S power holder

Claims (6)

[Claims] (1) A first substrate on which one or more photovoltaic elements are formed, or a multilayer plate in which a second substrate for surface protection is laminated on the light incident side of the photovoltaic elements on this first substrate, or the above-mentioned photovoltaic element. After laminating a multilayer board with a third reinforcing substrate laminated on the side opposite to the light incidence side of the power element on the fourth separating substrate,
By cutting, the first substrate or the first and second and/or third substrates are cut.
1. A method for manufacturing a photovoltaic device, comprising cutting the substrates at the same time, and holding and arranging one or more independently separated photovoltaic devices on a fourth substrate. (2) The photovoltaic device according to claim 1, characterized in that an adhesive layer containing an adhesive is inserted between each substrate when laminating the respective substrates to form a multilayer board. Production method. (3) When laminating each substrate to form a multilayer board, the second, third, and fourth substrates are laminated to the lead terminal portion of the photovoltaic element formed on the first substrate. Claim 1 characterized in that, and overlapping opening portions are provided.
A method for manufacturing a photovoltaic device according to item 1 or 2. (4) The lead terminal portion of the photovoltaic element has a conductive layer formed by a paste printing method, an electroless plating method, a solder dipping method, a solder reflow method, etc. 4. A method for manufacturing a photovoltaic device according to any one of Item 3. (5) A photovoltaic element characterized in that each of the first substrate, second substrate, third substrate, and fourth substrate is made of a resin film, and at least the first and second substrates are translucent. Production method. (6) A method for manufacturing a photovoltaic device, characterized in that the first substrate is made of translucent glass, the fourth substrate is made of a resin film, and the two substrates are laminated.